vintage parts marketing - flowserve...baseplate grouting requirements. copies of api recommended...

VINTAGE PARTS MARKETING PRODUCT LINE: DA - DAD HERITAGE COMPANY: Ingersoll-Rand CONFIGURATION: Horizontal split case

multistage - volute TYPICAL APPLICATION: Refinery, Pipeline, Industrial ,

Boiler Feed VINTAGE: 1979 - 2000 PRODUCT LIFESPAN: API 610 compliant, 7 th-8th

edition SUBJECT: Installation and Operations

Manual (IOM) The DA was a new product for IR, and was developed to compete with other volute multistage pumps – the DVMX (BJ), MSN (UCP, MSB (SB). It replaced the CNTA and HMTA. The DAD is the double suction first stage model. The DA became the DMX after the IDP acquisition. The DMX also includes some MX hydrauli cs. NOTE: This information is intended for the use of F lowserve Employees. The information provided is based on standard catal ogue / price book information. Details for specific units or serial n umbers may be different as a result of non-standard construction, and parts, r epairs and upgrades provided by Flowserve or third parties.

INSTALLATION OPERATION & MAINTENANCE

DAD PUMP I/B BALL/BALL CONFIGURATION

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READ THIS BEFORE PROCEEDING

It should be understood that the information contained in this manual does not relieve operating and maintenance personnel from the responsibility of exercising normal good judgement in the installation, operation, and mainte-nance of the pump and its components.

Only qualified personnel should work on this equipment, and only after reading this manual and becoming familiar with all of the safety notices and procedures contained herein. Safe and successful operation of this equipment is dependent upon its proper handling, installation, operation, and maintenance as described in this manual.

It should be understood that the contents of this manual do not add to or modify any prior or existing warranty, agreement, commitment, and/or relationship between Flowserve and the purchaser. The sales contract between the parties contains the sole warranty for this equipment.

During initial start-up of this equipment, it is recommended that the service of a Flowserve service supervisor be obtained to assure trouble-free operation. In some cases, the presence of a Flowserve service supervisor may be a contractual requirement for continuation of warranty. Check your contract.

To schedule a service supervisor, contact Flowserve Corporation, Customer Service Department (1-800-547-8671 or 908-859-7372), or contact the nearest Flowserve sales office.

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Table Of Contents

Section 1

Introduction

Pump Data Sheet 1-1

Approximate Weights 1-1

Introduction 1-2

Safety 1-2

Description 1-2

CASING 1-2

IMPELLERS 1-3

CASING RINGS 1-3

CHANNEL RINGS 1-3

CENTER SLEEVE 1-3

CENTER BUSHING 1-3

THROTTLING SLEEVE 1-3

THROTTLING BUSHING 1-3

SHAFT 1-3

SHAFT SLEEVES 1-3

BEARINGS 1-3

STUFFING BOXES 1-4

RECEIPT INSPECTION 1-4

UNPACKING 1-4

Care During Storage 1-4

Painting/Rust Preventive 1-4

Lifting Equipment 1-5

TO LIFT UNIT 1-5

TO LIFT DRIVER 1-5

TO LIFT PUMP 1-5

TO LIFT UPPER HALF CASING 1-5

TO LIFT PUMP ROTOR 1-5

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Extended Storage Requirements 1-5

GENERAL 1-5

INSPECTION UPON ARRIVAL 1-6

STORAGE AREA 1-6

STORAGE PREFERRED (DRY) 1-6

GENERAL 1-6

ROTOR STORAGE 1-6

INSPECTION AND MAINTENANCE 1-6

STORAGE NON-PREFERRED (WET) 1-8

Painting And Preservation 1-8

Start-Up 1-8

Drivers 1-8

Section 2

Installation

Location 2-2

Foundation 2-2

Installation Check List 2-2

Level The Bedplate 2-3

PRELIMINARY ALIGNMENT 2-3

Grouting 2-4

Shaft/Coupling Alignment 2-4

TYPES OF MISALIGNMENT 2-5

ALIGNMENT 2-5

HORIZONTAL MOVE 2-7

VERTICAL MOVE 2-8

CHECK COUPLING ALIGNMENT 2-8

ASSEMBLE AND LUBRICATE COUPLING 2-8

DOWEL PUMP AND DRIVER 2-8

HOT ALIGNMENT CHECK 2-9

ALIGNMENT DATA SHEET – SHEET 1 OF 2 2-10

ALIGNMENT DATA SHEET – SHEET 2 OF 2 2-11

ALIGNMENT DATA EXAMPLE 2-12

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Piping 2-13

SUCTION AND DISCHARGE PIPING 2-13

SUCTION STRAINER 2-14

Coupling Alignment Check 2-15

Gib Block Installation 2-15

Inspection Of Oil Rings Before Start-Up 2-16

Commissioning Of Equipment 2-16

Section 3

Operation

Technical Data 3-1

SPECIFIC GRAVITY 3-1

VISCOSITY 3-1

CHANGING PUMP SPEED 3-1

NET POSITIVE SUCTION HEAD (NPSH) 3-1

Operating Precautions 3-1

Pre-Operational Checks 3-2

PUMP INSTRUMENTATION SET POINTS 3-2

Initial Start-Up Procedure 3-3

Operating Checks 3-3

Normal Start-Up 3-4

Securing The Pump 3-4

Section 4

Troubleshooting

Troubleshooting 4-1

Flowserve Corporation Pump Service Centers 4-4

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Table Of Contents

Section 5

Lubrication

Lubricating Oil 5-1

Oil Specifications 5-1

Oil Temperature 5-2

Cleaning The Lubrication System Prior To Operation 5-2

Trico Oiler Setting 5-2

Section 6

Shaft Sealing

Mechanical Seal 6-1

MECHANICAL SEAL REMOVAL 6-1

Section 7

Maintenance

General 7-1

Preventive Maintenance Schedule 7-2

Torque Values 7-3

Coupling Removal 7-3

Dismantling Procedure 7-3

THRUST BEARING REMOVAL 7-3

PLAIN BEARING REMOVAL 7-4

REMOVAL OF STUFFING BOX PARTS 7-4

ROTOR REMOVAL 7-4

DISMANTLING THE ROTOR 7-5

HEATING IMPELLERS FOR REMOVAL 7-5

Inspection And Renewal Of Parts 7-6

Parting Flange Gasket 7-7

Parting Flange Torque Procedure 7-8

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Bearing Handling Information 7-8

BEARING HANDLING 7-8

BEARING INSTALLATION 7-9

BEARING REMOVAL 7-9

BEARING CLEANING 7-9

Reassembly Of Pump 7-10

REBUILDING ROTOR 7-10

INDICATE AND DYNAMIC-BALANCE ROTOR 7-11

INSTALLING ROTOR IN CASING 7-11

ASSEMBLE STUFFING BOX EXTENSION 7-12

CHECK ROTOR VERTICAL LIFT 7-12

CHECK ROTOR AXIAL FLOAT 7-12

HORIZONTAL AND VERTICAL SHAFT ALIGNMENT 7-13

CENTRALIZE ROTOR AXIALLY 7-14

SET THRUST BEARING END PLAY 7-14

INITIAL THRUST BEARING ASSEMBLY 7-15

FINAL THRUST BEARING ASSEMBLY 7-15

FINAL ASSEMBLY 7-16

Section 8

Parts Information

Service Instructions 8-1

Ordering Instructions 8-1

Recommended Spare Parts 8-2

Exploded View No. 1 – Typical Rotor Assembly 8-3

Exploded View No. 2 – Lower Half Bushings, Rotor & Casing Assembly 8-4

Exploded View No. 3 – Upper Half Bushings & Casing Assembly 8-5

Exploded View No. 4 – Shaft Sealing 8-6

Exploded View No. 5 – Plain Bearing End 8-7

Exploded View No. 6 – Thrust Bearing End 8-8

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Flowserve Corporation Pump Service Centers 8-9

Flowserve Corporation Domestic Sales Facilities 8-10

Flowserve Corporation International Sales Facilitie s 8-12

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Introduction

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PUMP DATA SHEET PURCHASER

LOCATION

FLOWSERVE ORDER

SERIAL NUMBERS

PUMP APPLICATION

LIQUID PUMPED

SPECIFIC GRAVITY

PUMP SIZE

DRIVER

PUMP RATING

NET POSITIVE SUCTION HEAD REQUIRED

NET POSITIVE SUCTION HEAD AVAILABLE

TOTAL HEAD

SUCTION PRESSURE

DISCHARGE PRESSURE

PUMP EFFICIENCY

BRAKE HORSEPOWER (design/max)

PUMP ROTATION

HYDROTEST PRESSURE

BEARING LUBRICATION

PUMP HOLD-DOWN TORQUE VALUE

APPROXIMATE WEIGHTS PUMP

DRIVER

BEDPLATE

TOTAL

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INTRODUCTION

This manual contains instructions for installation, operation and maintenance of your Flowserve Cen-trifugal pump. It has been designed to provide safe and reliable service. However, it is both a pressure vessel and a piece of rotating machinery. Therefore the operator(s) must exercise good judgement and proper safety practices to avoid damage to the equipment and surroundings and prevent personal injury.

The instructions in this manual are intended for the guidance of personnel with a general training in op-eration and maintenance of Centrifugal Pumps. It is our hope that you will become acquainted with its content as an aid to better pump performance. This manual should be read in its entirety before installing and/or operating the equipment. The Assembly Drawings (included in Appendix) and General Ar- rangement Drawing (included in Appendix) should be consulted for accurate details and determination of specific optional features that are furnished with your pump. All numbers in parentheses ( ) following part names correspond with “Exploded View” Noun Codes. EXAMPLE. (1-003A) – Exploded View #1, Noun Code #003A – Impeller Assembly. Exploded Views are included in Section 8.

NOTE

The installation/commissioning of this equipment must be conducted in accordance with API Recom-mended Practices 686/PIP REIE 686 – First Edition. Refer to API 610 – Eighth Edition – Appendix `L’ for baseplate grouting requirements.

Copies of API Recommended `Practices 686/PIP REIE 686 – First Edition’ may be obtained from – America Petroleum Institute, 1220 L Street, N.W., Washington, DC 20005. Telephone (202) 682-8000.

SAFETY

It is assumed that your safety department has established a safety program based upon a thorough analysis of industrial hazards. Before installing and operating or performing maintenance on the pump and associated components described in this man-ual, the safety program must be reviewed to ensure that it covers the hazards arising from high- speed rotating machinery.

It is also important that due consideration be given to those hazards which arise from the presence of electrical power, hot oil, high-pressure and high-temperature liquids, toxic liquids and gases and flammable liquids and gases. Proper installation and care of protective guards, shutdown devices and over-pressure protection equipment should also be considered a mandatory part of any safety program.

Also essential are special precautionary measures to prevent the possibility of applying power to the equipment at any time when maintenance work is in progress. The prevention of rotation due to reverse flow should not be overlooked.

In general, all personnel should be guided by all the basic rules of safety associated with the equipment and the process.

DESCRIPTION

The “DAD” pump is a multistage, opposed impeller, horizontally split volute pump.

The first stage is double suction; remaining stages are single suction.

The suction and discharge nozzles are cast integral with the lower half casing.

Rotating parts are accessible by removing the up-per-half casing which can be removed without breaking suction and discharge piping.

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CASING

The casing provides for immediate containment of the liquid being pumped, while directing the flow of liquid from the suction nozzle to the impellers and subsequently through the volute to the discharge nozzle.

The casing halves are sealed by the use of a gasket and are joined together by studs, which are installed in the lower half casing and fastened with washers and cap nuts.

IMPELLERS

The impellers are enclosed type, one-piece con-struction and are dynamically balanced.

The first stage is double suction; remaining stages are single suction.

They are fitted with renewable impeller rings (front and back) which are held in place by headless set- screws.

The impellers are keyed, have a shrink fit to the pump shaft and are held in axial position by a split ring.

CASING RINGS

Casing rings are positioned over the impeller front rings. These rings are tubular and renewable.

CHANNEL RINGS

Renewable channel rings are positioned over the impeller back rings. They divide the casing into stages. These rings are horizontally split and are held together by shoulder screws.

CENTER SLEEVE

A renewable type center sleeve is used under the center bushing. The center sleeve is tubular and keyed to the shaft (via the impeller key).

CENTER BUSHING

The renewable center bushing is horizontally split, the two halves are held together by socket-head capscrews and taper dowel pins. It is held in position by the raised annular ring of the bushing engag-ing the annular groove in the casing.

The center bushing, in conjunction with center sleeve, divides the casing at the center (back-to-back) impellers.

THROTTLING SLEEVE

Renewable type throttling sleeve is used under the throttling bushing. The throttling sleeve is tubular, keyed, has a shrink fit to the shaft, and is held in position by a split ring.

THROTTLING BUSHING

Renewable type throttling bushing is used. It is held in position by the annular ring of the bushing en- gaging the annular groove in the casing.

The throttling bushing, in conjunction with the throttling sleeve, allows pressure to be bled off thru the balance lines, so that pressure on the stuffing boxes is balanced. The throttling bushing also balances the axial thrust of the pump rotor.

SHAFT

The high-strength shaft is ground over its entire length to close tolerances. The shaft is designed to transmit the required power without vibration and is stepped at each impeller fit for ease of assembly and disassembly.

SHAFT SLEEVES

Renewable shaft sleeves are provided with pumps equipped with packed stuffing boxes to protect the shaft at the stuffing box areas. The sleeves are tu-bular type, keyed to the shaft, and held in position by the retaining rings.

BEARINGS

The plain and thrust ball bearings are lubricated by means of oil rings, which run on journal sleeves and in the oil reservoir of the bearing housings.

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The plain ball bearing is a single-row deep-groove type, free to adjust axially in the bearing housing.

The thrust ball bearing is of the double-row (mounted back-to-back) angular-contact type, and is of ample size to carry the thrust loads encountered in service. The pump bearings are renewable.

STUFFING BOXES

The stuffing boxes are cast integral with the casing. The suction and discharge end stuffing boxes can be equipped with a cartridge type mechanical seal or stuffing box packing.

RECEIPT INSPECTION

NOTE

The following information regarding receiving is only offered as a general guideline to the customer. Flowserve Corp. requires that all receiving be con-ducted in accordance with specifications set forth in Chapter 3 -`Jobsite Receiving and Protection’ from API Recommended Practices 686/PIP REIE 686, First Edition.

The pump and its associated equipment were carefully inspected at the factory prior to shipment to ensure compliance with the purchase requirements and job specification. It is suggested that the pump be inspected upon arrival and that any irregularities or damage be reported to the carrier immediately.

The condition of the skid and covering is indicative of the way the shipment was handled. Broken skids, torn coverings, bent hold-down bolts, broken straps, etc. indicate rough handling.

The protective covers on the pump nozzles should be in place and undamaged. The shipping papers should be checked to determine satisfactory arrival of any special tools, loose parts, and/or spare parts, etc., which are usually preserved and packed in a separate box attached to the skid.

If any damage is discovered and/or parts are miss-ing, notify the carrier or nearest Flowserve office immediately.

UNPACKING

The pump should arrive already mounted on the bedplate and it is therefore suggested that the unpacking of the equipment should proceed per instruction as outlined in this manual.

In general, care is to be taken when removing crat-ing, coverings, and strapping in order not to damage any auxiliary equipment and/or the paint finish.

CARE DURING STORAGE

(see “Extended Storage Requirements”)

If it is necessary to store the unit any length of time before installation, find a vibration-free location that is protected from unfavorable weather.

The nozzle covers provided with the unit should be left in place during storage.

Electric motors (pump driver) should not be stored in damp places without special protection (refer to mo-tor manufacturer’s instructions).

PAINTING/RUST PREVENTIVE

Internal parts of the pump and bearing housings are protected prior to shipment with a thin-film polar-type rust preventive [pump internals (Ferrocote 5684), bearing housings (MIL-C-16173 Grade 3)]. This can be removed by flushing with natural citrus solvent.

External machined surfaces are protected with dura- ble drying-type rust preventive (MIL-C-16173 Grade 1). This can be removed with kerosene or safety solvent (Tower No. 392).

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External non-machined surfaces are painted with one coat of gray enamel followed by a coat of multi- color speckle lacquer.

Exception: External non-machined surfaces of the pump [if operating at a temperature above 200oF. (94oC)] are painted with a high-temperature alumi-num base paint.

Parts ordered separately are protected with a thin-film polar-type rust preventive. This can be removed with petroleum solvents.

LIFTING EQUIPMENT

NOTE

The following information regarding lifting is only offered as a general guideline to the customer. Flowserve Corp. requires that all lifting and rigging be performed in accordance with specifications set forth in Chapter 2 - `Lifting and Rigging’ from API Recommended Practices 686/PIP REIE 686, First Edition.

WARNING MAKE SURE THAT ANY EQUIPMENT USED TO LIFT THE PUMP OR ANY OF ITS COMPONENTS IS CAPABLE OF SUPPORTING THE TOTAL WEIGHT ENCOUNTERED. MAKE SURE THAT ALL PARTS ARE PROPERLY RIGGED BEFORE ATTEMPTING TO LIFT.

TO LIFT UNIT

Pump, driver and bedplate can NOT be lifted as a unit. Driver must be removed from bedplate before lifting.

To lift pump and bedplate or just bedplate, sling bedplate from all lifting eyes. Failure to do this may result in permanent deformation of bedplate.

TO LIFT DRIVER

Refer to driver manufacturer’s instructions.

TO LIFT PUMP

Install sling from overhead hoist and under bearing housing mounting brackets (cast portion of casing where bearing housings attach).

WARNING DO NOT LIFT ENTIRE PUMP FROM CAST LIFT- ING LUGS ON UPPER HALF CASING. THESE LUGS ARE FOR LIFTING UPPER HALF CASING ONLY.

TO LIFT UPPER HALF CASING

Rig to overhead hoist from cast lifting lugs provided.

TO LIFT PUMP ROTOR

Using slings that will not damage shaft, rig around shaft close to the impellers and to overhead hoist. Carefully lift rotor from lower half casing.

EXTENDED STORAGE REQUIREMENTS

NOTE

The following information regarding receiving is only offered as a general guideline to the customer. Flowserve Corp. requires that all receiving be con-ducted in accordance with specifications set forth in Chapter 3 –`Jobsite Receiving and Protection’ from API recommended Practices 686/PIP REIE 686, First Edition.

GENERAL

During extended periods of storage prior to installation and from the time of installation until commercial operation, precautions must be taken to protect the pump from deterioration. The various parts of the pump are protected prior to shipment by applying varying grades of preservatives and paint. However, during shipment and handling, the preservatives are subjected to conditions that can cause their removal. Also, during extended periods of time, the pre-servative may deteriorate. The following procedures should be followed to prevent deterioration of the pump during the extended storage period. These procedures may also be supplemented by the ex-perience of the person(s) performing the tasks.

Introduction

1-6

It should be noted, that unless otherwise agreed to, full responsibility and costs associated with the stor-age and inspection of this equipment rests with the customer.

CAUTION IF PUMP IS EQUIPPED WITH A MECHANICAL SEAL AND IS STORED OR HAS NOT BEEN RUN FOR 1 YEAR OR MORE, THE MECHANICAL SEAL MUST BE REMOVED BEFORE START-UP AND FACES RE-LAPPED TO GUARD AGAINST THE POSSIBILITY OF SEAL LEAKAGE. WHEN RE-INSTALLING THE SEAL, NEW "O” RINGS AND GASKETS MUST BE USED.

INSPECTION UPON ARRIVAL

When the pump is received, it should be inspected for damage or other signs of rough handling. Any damage found should be reported to the carrier immediately.

Inspect the preservative coating on the various parts. If necessary, renew the preservative in areas where it has been rubbed off or scraped.

Inspect all painted surfaces. If necessary, touch up the areas where paint has been chipped or scraped.

Inspect all covers over pump openings and piping connections. If covers or seals for the covers are damaged or loose, they are to be removed, and a visual inspection made of the accessible interior ar-eas for accumulation of foreign materials or water. If necessary, clean and recoat the interior parts with preservative to restore the parts to the “as shipped” condition. Install or replace covers and fasten se-curely.

STORAGE AREA

When selecting a storage area, the following should be taken into consideration:

1. The deterioration of the equipment will be proportionate to the class/type of storage provided.

2. The expenses involved in restoring the equipment at time of operation will be proportionate to the class/type of storage provided.

STORAGE PREFERRED (DRY)

GENERAL

If at all possible, the pump and its components should be stored indoors where they will be protected from the elements. If it is not possible to store the pump and its components indoors, precautions must be taken to protect them from the elements. Regardless of whether storage is inside or outside, the storage area should be vibration-free. All boxes that are marked for inside storage must be stored indoors. The pump and its components, when stored outdoors, should be protected from dirt, dust, rain, snow or other unfavorable conditions by cover-ings of heavy-gauge plastic sheets, canvas, water-proof burlap or other suitable coverings.

All equipment must be placed upon skids or blocks to prevent contact with the ground and surface con- taminants. Equipment must be adequately supported to prevent distortion and bending.

ROTOR STORAGE

It is recommended that pump rotor be stored in the pump. Multistage diffusor-type pump rotors that cannot be stored in the pump must be supported at the channel rings so that rotor weight is evenly distri- buted. Single-stage and volute-type pump rotors not stored in pump must be supported close to im- pel-ler(s) to eliminate sag that may cause rotor to take a permanent set.

INSPECTION AND MAINTENANCE

1. Customer Inspection And Maintenance

The stored equipment is to be placed on a periodic inspection schedule by the customer.

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NOTE

The responsibility for setting up an inspection and maintenance schedule rests with the customer and will be dependent upon the class/type of storage provided. It would be expected that initially in- spec-tion would occur weekly, then depending upon the inspection reports being favorable or unfavorable, inspection would continue weekly, monthly, or quar-terly, as may be determined. Inspection reports must be kept on file.

Each inspection should consist of a general surface inspection.

(a) Pump supports are firmly in place.

(b) Pump covers over openings are firmly in place.

(c) Pump covering, plastic or tarps, is firmly in place. Any holes or tears must be repaired to prevent en-trance of dirt or water.

(d) Pump rotors stored in pump should be rotated 1-1/4 revolutions at least once a week to prevent rotor from taking a permanent set.

CAUTION IF PUMP IS EQUIPPED WITH SLEEVE BEAR- INGS THE OIL RING INSPECTION PLUG ON TOP OF THE BEARING HOUSING IS TO BE REMOVED AND A SMALL AMOUNT OF OIL POURED OVER THE JOURNALS BEFORE TURNING.

Single-stage and volute-type pump rotors stored separately should be rotated 1-1/4 revolutions weekly.

(e) Pump covers are periodically removed from openings and interior accessible areas inspected. If surface rusting has occurred, clean and repaint or recoat with preservative.

(f) If rusting occurs on exterior surfaces, clean and repaint or recoat with preservative.

(g) Loosen casing drain plugs to allow seepage of any accumulated moisture.

(h) Periodically remove bearing covers and inspect for accumulation of moisture, rust and foreign mate-rial. As required, clean bearings and bearing hous-ing and represerve. Install bearing cover and secure to assure maximum protection. Bearings removed for storage should be coated with preservative, wrapped in oil/wax paper, and stored in a warm dry area.

(i) Check individually wrapped parts for signs of deterioration. If necessary, renew preservative and wrapping.

2. Six Months Prior To Installation

Six months prior to the scheduled installation date, a Flowserve Corporation representative is to be em-ployed to conduct an inspection. All costs involved during inspection, dismantling, restoration, replace-ment of parts, and reassembly will be the responsi-bility of the customer. All necessary labor, tools, and cranes will be supplied by the customer. This in-spection will include (not necessarily in its entirety) but not be limited to, the following:

(a) An inspection of all periodic inspection records as kept on file by the customer, and all inspection reports that have been compiled during the storage period.

(b) An inspection of the storage area to determine the “as stored” condition of the equipment prior to any protection covers being removed.

(c) An inspection of the equipment with protection covers and flange covers removed.

(d) Depending upon the length of time the equipment was stored, the class/type of storage provided, (i.e.: indoor, heated, unheated, ground floor, concrete floor, out-of-doors, under roof, no roof, water- proof covering, on concrete, on ground) and as a result of the inspection of a, b and c above, the Flowserve representative may require a partial or complete dismantling of the equipment.

(e) Dismantling may necessitate restoration of painted or preserved surfaces, and/or replacement of gaskets, “O” rings, packing, and/or mechanical seal and bearings. Use only Flowserve recom-mended replacement materials.

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Upon completion of the inspection, the Flowserve Corporation representative shall submit a report to the customer, and to the Manager of Customer Ser-vice, stating in detail the results of the inspection.

3. One Month Prior To Installation

One month prior to installation of the equipment, a Flowserve Corporation representative is to be em-ployed to conduct a final inspection. This final in-spection will be made to assure that the require-ments of the six-month inspection report were satis-factorily completed and that the equipment is ready for installation.

Upon completion of this inspection, the Flowserve Corporation representative shall submit a final report to the customer, and to the Manager of Customer Service, advising the results of the final inspection.

STORAGE NON-PREFERRED (WET)

It is not recommended that the rotor be subjected to extended periods of submergence or wetting prior to start-up. However, it is recognized that in some cases, a long period of time may lapse from installation until commercial operation.

If the pump must be stored after being installed and wetted, the following inspection and maintenance procedures should be performed.

1. Isolate pump with valving – tag (seal) all valves.

2. Preserve the pump internals.

(a) Corrosive Pumpage.

Fill pump with a 1% solution of Immunol 1809 and water, (or owner-approved preservative). Immunol is a water-phase corrosion inhibitor for ferrous and mixed-metal couples and is composed of 5% sodium nitrate with polyglycols, copper corrosion inhibitor, and other organic materials. The pump should be filled to highest level possible, affording the greatest protection possible to all internal parts of the pump. This solution, when drained, will result in a thin resi- dual oil film (less than .0005 in.(.0127 mm) on all internals after the water has evaporated. This resi-due provides added corrosion protection until pump is again filled with liquid or put into service.

(b) Non-Corrosive Pumpage.

Fill pump with pumpage to the highest level possi-ble. Periodically open drain connection to drain off any moisture that may have accumulated. Refill to highest level possible. Drain and inspect pump prior to start-up.

3. Rotate pump rotor 1-1/4 revolutions at least once a week. Make sure bearings have adequate lubrication before turning rotor.

4. Periodically remove bearing covers and inspect for accumulation of moisture, rust and foreign mate-rial. As required, clean bearings and bearing hous-ing and represerve. Install bearing cover and secure to assure maximum protection.

PAINTING AND PRESERVATION

Paints and preservatives used are either Flowserve Corporation standard or special as required by the contract specification. Refer to “RUST PREVEN-TIVE” for the description of paints and preservatives used on this order or contact the branch office through which the order was placed.

START-UP

Prior to and during start-up, any requirement for the services of a Flowserve Corporation representative will revert to the original contract agreement for the equipment purchased.

DRIVERS

Generally storage must be indoors and dry. See the specific manufacturer’s storage requirements.

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NOTE

The installation/commissioning of this equipment must be conducted in accordance with API Recommended Prac-tices 686/PIP REIE 686 - First Edition. Refer to API 610 - Eighth Edition - Appendix `L` for baseplate grouting re-quirements.

Copies of API Recommended ‘Practices’ 686/PIP REIE 686 - First Edition may be obtained from - America Petro-leum Institute, 1220 L Street, N.W., Washington, D.C. 20005. Telephone: (202) 682-8000.

The following ASTM Specifications are furnished as references for test methods used in conjunction with installa-tion of grouting materials and should be used to obtain proper results.

ASTM C 78-84 Test Method for Flexural Strength for Concrete.

ASTM C 109-90 Test Method for Compressive Strength of Hydraulic Cement Mortars - Modified.

ASTM C 469-87a Test Method for Static Modulus of Elasticity and Poisson’s Ratio of Concrete in Compres-sion.

ASTM C 496-90 Test Method for Splitting Tensile Strength of Cylindrical Concrete Specimens.

ASTM C 531-85 Test Method for Linear Shrinkage and Coefficient of Thermal Expansion of Chemical Re-sistant Grouts and Monolithic Surfacings - (Modified).

ASTM C 666-90 Test Method for Resistance of Concrete to Rapid Freezing and Thawing.

ASTM C 939-87 Test Method for Flow of Grout for Preplaced Aggregate Concrete (Flow Cone Method).

ASTM C 942-86 Test Method for Compressive Strength of Grouts for Preplaced Aggregate Concrete in the Laboratory.

ASTM C 1090-88 Test Method for Measuring Changes in Height of Cylindrical Specimens from Hydrau-lic Cement Grout.

ASTM C 1107-91 Standard Specification for Packaged Hydraulic-Cement Grout (Non-Shrink).

(CRD-C 621-92) ACI 351 Grouting for Support of Equipment and Machinery. 24 Hour Test MBT Test Method for Grout Performance.

MINIMUM REQUIREMENTS FOR EPOXY GROUT [TYPICAL PROPERTIES AT 73oF.(23oC.)]

ASTM D-635 Fire Resistant

ASTM C-579B Minimum Compressive Strength – 12000 psi

ASTM C-827 Height Change @ 90oF.(38oC.) – Positive – Effective Bearing Area – 95%

ASTM C-1181 Maximum Creep in 1 Year – 1.6X10-3in/in at 140oF., 400 psi

ASTM C-307 Minimum Tensile Strength – 1800 psi (12.4 MPa)

ASTM C-580 Minimum Flexural Strength – 3800 psi (26.2 MPa)

ASTM C-580 Minimum Flexural Secant Modulus – 1.8X106 psi (1.2X104 MPa)

ASTM C-531 Maximum Coefficient of Expansion – 17X10-6in/in/oF. Maximum Peak Exotherm 1000 gm insulated – 95oF.(35oC.) Full Aggregate Must Be Used.

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LOCATION

Install the unit close to the source of the liquid to be pumped.

When selecting the location, be sure to allow ade-quate space for operation as well as for mainte- ance operations involving dismantling and inspection of parts.

Head room is an important consideration, as an overhead lift of some type is required.

FOUNDATION

NOTE

The following information regarding foundation is only offered as a general guideline to the customer. Flowserve Corp. requires that all foundations be de-signed/installed in accordance with specifications set forth in Chapter 4 - `Foundations’ from API Recom-mended Practices 686/PIP REIE 686, First Edition.

The design of foundations, is not the responsibility of Flowserve Corp. It is therefore recommended that the customer consult a competent specialist skilled in the field of foundations, to insure proper design/ installation of the foundation.

The foundation should be sufficiently rigid and sub- stantial to prevent any pump vibration and to perma- nently support the bedplate at all points.

The most satisfactory foundations are made of rein- forced concrete. These should be poured well in advance of the installation to allow proper time for drying and curing.

The General Arrangement Drawing will furnish an- chor bolt locations, size of bolts, etc.

Template For Hanging Foundation Bolts

The sketch illustrates a recommended foundation bolt arrangement. Notice the large washer with lugs at the bottom. It should be welded to the bolt and pipe sleeve to prevent turning.

Allow a little more than the specified threaded bolt length above the rail of the baseplate. The excess can always be cut off it not needed.

A rough finish top surface is best when applying grout.

INSTALLATION CHECK LIST

1. Level Bedplate

2. Preliminary Alignment

3. Grout Bedplate

4. Align Shaft/Coupling

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5. Piping

6. Check Coupling Alignment

LEVEL THE BEDPLATE

NOTE

The following information regarding leveling of equipment is only offered as a general guideline to the customer. Flowserve Corp. requires that all lev-eling of equipment be performed in accordance with specifications set forth in Chapter 5 - `Mounting Plate Grouting’ from API Recommended Practices 686/PIP REIE 686, First Edition.

Before putting the unit on the foundation, thoroughly clean the top of the foundation. Break off any loose pieces of cement and roughen the top with a chisel to afford a good hold for grout.

NOTE

Coupling bolting and spacer piece (when used) must be removed from between pump/driver half couplings before lifting baseplate with pump element.

NOTE

When lifting bedplate with pumping element, sling bedplate from all lifting eyes provided. Failure to do this may result in permanent deformation of bedplate.

Prepare enough iron wedges or shims to be placed on each side of each foundation bolt. These wedges should be about 4 in.(102 mm) to 6 in.(152 mm) long by 2 in.(51 mm) to 3 in.(76 mm) wide and thick enough to allow for 1-1/4 in.(32 mm) of grout under the edge of the bedplate. Place wedges as shown in sketch.

Level the bedplate by using a machinist’s level on the machined surfaces of the pump and driver pads. When the bedplate is leveled, pull down the foundation bolts so they are snug. The bedplate may have been disturbed by tightening the foundation bolts; therefore, recheck with level and make necessary adjustments by wedges or shimming.

As a final bedplate alignment check on spacer type couplings, install a mounting bracket for dial indicator on driver hub. Fasten or clamp indicator on mounting bracket, so that dial indicator button is contacting the face of the pump half coupling, and zero the dial indicator. (Non-spacer type coupling should be check with tapered wedge or feeler gages.)

Rotate the driver half coupling (in direction of pump rotation) 90o. Record this reading.

Repeat this procedure until readings have been taken at four 90o positions.

PRELIMINARY ALIGNMENT

Using the previous procedure, shim and/or wedge bedplate until pump and driver are within .003 in. (.076 mm).

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GROUTING

NOTE

The following information regarding grouting is only offered as a general guideline to the customer. Flowserve Corp. requires that all grouting be in-stalled in accordance with specifications set forth in Chapter 5 - `Mounting Plate Grouting’ from API Rec-ommended Practices 686/PIP REIE 686, First Edi-tion.

It is recommended that the customer consult a competent specialist skilled in the field of grouting, to insure the proper installation of all grouting.

Build a dam around the foundation. It is a matter of personal preference whether the leveling wedges un-der the bedplate should be removed after grouting. If you do want to remove the wedges, carefully mark their locations before pouring grout.

Build Dam Around Foundation Before Pouring Grout

Use a quality, high strength, non-shrink epoxy grout - mix and install per manufacturer’s instructions.

Holes are provided in the bedplate to permit pouring the grout and stirring. They also act as air vents. Fill under the bedplate completely, stirring to assure proper distri-bution of the grout. Check to see that the grout flows under the edges of the bedplate evenly.

NOTE

Do not vibrate bedplate when grouting; make sure bed-plate is vented properly and all areas indicated on Gen-eral Arrangement drawing are thoroughly puddled to prevent any resonant problems.

When the grout is thoroughly hardened, remove the dam and wedges, if desired, filling in the holes they leave with grout.

SHAFT/COUPLING ALIGNMENT

NOTE

The following information regarding shaft alignment is only offered as a general guideline to the customer. Flowserve Corp. requires that all shaft alignment be performed in accordance with specifications set forth in Chapter 7 - `Shaft Alignment’ from API Rec-ommended Practices 686/PIP REIE 686, First Edi-tion.

CAUTION SHAFT ALIGNMENT MUST BE CORRECT FOR SUCCESSFUL OPERATION. RAPID WEAR , NOISE, VIBRATION AND ACTUAL DAMAGE TO THE EQUIPMENT MAY BE CAUSED BY SHAFT MIS-ALIGNMENT. THE SHAFTS MUST BE ALIGNED WITHIN THE LIMITS GIVEN WITHIN THIS SECTION.

NOTE

Adjustments to correct the alignment in one direction may alter the alignment in another direction. Always check in all directions after making any adjustments.

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Coupled equipment must be aligned to minimize un- necessary stresses in shafts, bearings and coupling. Flexible couplings will not compensate for appreci- able misalignment. Foundation settling, thermal expansion or nozzle loads resulting in baseplate/foundation deflection and vibration during operation may require the full coupling misalignment capability.

TYPES OF MISALIGNMENT

There are two types of shaft misalignment: Angular and offset. Therefore, two sets of measurements and corrections are required. Both types of misalignment can occur in horizontal and vertical planes and are present in most applications.

A. Angular Misalignment

In angular misalignment, the centerline of the shafts intersect, but are not on the same axis.

B. Offset Misalignment

In offset misalignment, the shaft centerline are parallel but do not intersect.

Offset Misalignment

Combination Offset And

Angular Misalignment

ALIGNMENT

A. Measure Gap

The first step in shaft/coupling alignment is to bring the pump and driver shafts into their proper axial position. The shaft gap, or distance between coupling hubs, must be in accordance with the certified General Arrangement Drawing and must be measured with pump and driver shafts in the center of their axial end float. Motor with sleeve bearings is to be aligned with rotor at magnetic center.

Move driver to insure proper gap distance.

NOTE

It is recommended that the pump hold-down bolting be torqued and the pump be dowelled before taking any alignment measurements. This makes the pump the fixed machine and the driver the movable machine. In certain cases, however, it may be impractical to move the driver; therefore, the pump may have to be moved. When this case exists, the pump should not be dow-elled until after final alignment.

B. Measure Angular Misalignment

Refer to “ALIGNMENT DATA SHEET” and exam-ples.

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CAUTION PUMP SHAFT SHOULD NOT BE ROTATED MORE THAN NECESSARY WHEN ALIGNING SHAFTS. DAMAGE COULD OCCUR TO INTERNAL WEARING PARTS WHICH ARE LUBRICATED BY THE PUMP LIQUID.

The angular misalignment can best be determined by the use of a hand-held inside micrometer, marked “B” on sketch. All measurements should be taken at the same radial distance from the shaft centerline, as close as possible to the hub outside diameter. The location of these measurements is defined as the “D” dimension on the “ALIGNMENT DATA SHEET”. Do not move the shafts axially while rotat-ing the shafts and taking measurements. Both hubs must be rotated together to cancel possible hub face runout. The relative measurement (top minus bot-tom, right minus left) is the important number.

1. Mark both coupling hubs at 3,6,9 and 12 o’clock positions so they can be rotated together and at 90o intervals.

2. Starting with the 12 o’clock markings of both hubs in the top center position, measure the gap at top, bottom, right and left side. Record these di-mensions on “ALIGNMENT DATA SHEET” Sheet 1, Part 1 in the 0o Column.

NOTE

Right side and left side are determined when viewing the driver coupling from the pump.

3. Rotate both shafts 90o in the direction of pump rotation. Measure gap dimensions at the four locations as in Step 2. Record on “ALIGNMENT DATA SHEET”-Sheet 1, Part 1 in the 90o Column.

4. Repeat Step 3 until measurements have been taken at the four positions (0o,90o,180o,270o).

5. Rotate both shafts to the starting position (12 o’clock markings at top center) and recheck dimension recorded in Step 2.

6. For 0o,90o,180o,270o Columns, subtract the bottom from the top and left from right. Record in their respective blocks on Data Sheet. Watch sign nota- tions.

7. Total the different numbers (reading across), divide by 4 and record the average_____. Record in “Open At _____” the shaft relative angular position.

NOTE

The inside faces of the driver and pump half hubs must be parallel within .001 in.(.0254 mm).

C. Measure Offset Misalignment

Offset misalignment is measured using a dial indicator on the outside diameter of the coupling hubs and rotating the hubs together to cancel rim surface inaccuracies.

1. Starting with the 12 o’clock markings of both hubs on top center, fasten or clamp an indicator on driver hub, marked “A” on sketch, with dial indicator button contacting alignment surface on the pump hub.

2. Zero the dial indicator.

3. Rotate both coupling hubs (in the direction of pump rotation) 90o and take a reading. Record on “ALIGNMENT DATA SHEET”-Sheet 1, Part 2 in the proper right side or left side blank (right or left sides are determined when viewing the driver half coupling from the pump).

4. Repeat Step 3 until readings have been taken at the four 90o positions (top center, right, bottom and left).

5. Rotate both shafts to the starting position (12 o’clock markings at top center) and verify indicator returns to zero.

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NOTE

The sum of the top and bottom readings should al-ways equal the sum of the left and right readings. If the sums are not equal, check for indicator bracket deflection, hub surface irregularity or loose radial bearings.

6. Using the formula on “ALIGNMENT DATA SHEET”-Sheet 1, Part 2, subtract the top from the bottom indicator reading, divide by 2. This will yield the vertical misalignment.

7. Using the formula on “ALIGNMENT DATA SHEET”-Sheet 1, Part 2, subtract the left from the right indicator reading, divide by 2. This is the horizontal misalignment.

8. Circle the proper high or low and left or right position of the driver hub, using the rules given on the Data Sheet.

NOTE

The outside diameters of pump and driver coupling hubs must be aligned within .003 in.(.0762 mm) TIR.

D. Movement Calculations (“ALIGNMENT DATA SHEET”-Sheet 2).

1. Sketch the relative driver shaft position in the side and top views. These sketches will assist visu-alizing the required equipment move.

2. Alignment depends upon the relationship between D, LI and Lo.

Use the formula G X L to determine the required move. D

NOTE

D = Diameter of the circle at which angular misalignment readings were taken (not coupling diameter).

Gy = Gap difference (top minus bottom) taken from sheet 1, Part 1.

GH = Gap difference (right minus left) taken from Sheet 1, Part 1.

LI = Distance from driver coupling hub to cen-terline of driver inboard hold-down bolt.

LO = Distance from driver coupling hub to cen-terline of driver outboard hold-down bolt.

3. Record vertical offset from Sheet 1, Part 2 and vertical move obtained from calculations in the “IN- BOARD”, and OUTBOARD DRIVER PEDESTAL SHIFT” columns. Also record the required direction of shift (raise or lower).

4. Record horizontal offset from Sheet 1, Part 2 and horizontal move obtained from calculations in the “INBOARD, and OUTBOARD DRIVER PEDESTAL SHIFT” columns. Also record the required direction of shft (right or left).

5. Total the move requirements (watch move direction). This will yield the required horizontal move (right or left) and the vertical move (raise or lower) required at each mounting foot.

HORIZONTAL MOVE

The dial indicators shown below are required to ac- curately measure the move in the horizontal direction. Move the driver by bumping with soft ham-mer/mallet or using the jackscrews (if provided). The amount of horizontal relocation required is the total of the horizontal move calculation (bottom of Sheet 2).

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VERTICAL MOVE

Before moving the equipment vertically, it is im-portant that the vertical thermal expansion be taken into consideration. The preceding vertical move cal-culations are based on pump and driver shafts being set on the same plane. Refer to General Arrange-ment Notes and/ or driver instructions for recom-mended cold vertical setting (if thermal expansion is a factor).

The shims between the equipment feet and mount-ing surface should be clean and dry. This is espe-cially critical for pumps that have been in service for some time and need to be realigned. Water, dirt and rust may change the height of the shim pack over a period of time. Shims should be made large enough to support the weight of the equipment on its mount-ing foot. Do not use many thin shims, as this may result in a spongy mounting.

Recommended Shim Design

Move the equipment vertically by adding or remov-ing the calculated thickness of shims. Torque equip-ment hold-down bolting to required values.

NOTE

It is recommended, the completed “ALIGNMENT DATA SHEET” be retained as part of your permanent maintenance file.

CHECK COUPLING ALIGNMENT

The angular and offset coupling alignment must be rechecked.

1. Coupling faces are to be parallel within .001 in.(.0254 mm) TIR.

2. Coupling outside diameters are to be aligned within .003 in.(.0762 mm) TIR.

3A. Motor-Driven: “Bump” the motor and check mo-tor rotation (see “Troubleshooting”).

3B. Turbine-Driven: Check turbine rotation. (If wrong, consult turbine manufacturer.)

ASSEMBLE AND LUBRICATE COUPLING

1. Assemble and lubricate coupling per the manu-factur- er’s instructions included in “Appendix” of this manual.

2. Install coupling guard.

DOWEL PUMP AND DRIVER

A. Cold Pumps [temperature below 200oF.(94oC.)]

Pump hold-down bolts are to be torqued to the proper value and dowel pins put in two diagonally opposite feet.

B. Hot Pumps

Pumps handling liquids at temperatures of 200oF. (94oC.) and over are designed to permit the casing to expand with temperature away from coupling end of pump. The units that come under this classifica-tion must have the pump supports or feet dowelled to the baseplate at the coupling end. This maintains the coupling gap at the desired amount.

The pump feet at the opposite end are held from moving vertically by the use of a self locking nut. The clearance between the base of the nut and the top of the pump foot should be .002 in.(.051 mm).

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The horizontal movement is controlled by a “Gib block” running parallel to the length of the pump at each of the outboard feet. The “Gib Blocks” are bolted and dowelled to the baseplate at the time of mounting at the factory. A .010 in.(.254 mm) gap is maintained between the “Gib Block” and pump foot.

IMPORTANT

The self locking nuts which hold the pump from moving in a vertical motion are clamped tight to the pump foot at time of shipment. The .002 in.(.051 mm) clearance must be established at time of in-stallation.

C. Pump Driver

Refer to driver outline drawing and/or driver instructions for dowelling information.

HOT ALIGNMENT CHECK

A hot check can only be made after the unit has been in operation a sufficient length of time to assume its NORMAL operating temperature and conditions. If the unit has been properly cold set, the offset misalignment will be within .003 in.(.076 mm) TIR and the angular misalignment will be within .001 in.(.0254 mm) TIR when in operation. If not, make adjustments.

WARNING DO NOT ATTEMPT ANY MAINTENANCE, IN-SPECTION, REPAIR OR CLEANING IN THE VICINITY OF ROTATING ELEMENT. SUCH ACTION COULD RESULT IN INJURY TO OPERATING PERSONNEL.

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WARNING BEFORE ATTEMPTING ANY INSPECTION OR REPAIR ON THE PUMP, THE DRIVER CONTROLS MUST BE IN THE “OFF” POSITION, LOCKED AND TAGGED TO PREVENT INJURY TO PER- SONNEL PERFORMING SERVICE ON THE PUMP.

PIPING

NOTE

The following information regarding piping is only offered as a general guideline to the customer. Flowserve Corp. requires that all piping and related systems be designed/installed in accordance with specifications set forth in Chapter 6 -`Piping’ from API recommended practices 686/PIP REIE 686, First Edition.

The design of piping, and related systems, is not the responsibility of Flowserve Corp. It is therefore rec-ommended that the customer consult a competent specialist skilled in the field of piping, to insure proper design/installation of all piping.

SUCTION AND DISCHARGE PIPING

These units are furnished for a particular service condition. Changes in the hydraulic system may affect performance adversely. This is especially true if the changes reduce the pressure at the suction flange. In case of doubt, contact the nearest Flows-erve Office.

Suction and discharge piping should be of ample size, be installed in direct runs, and have a minimum of bends.

NOTE

Provision must be made to support piping external to the pump to prevent excessive nozzle loads and maintain pump-driver alignment.

Install a check valve and a gate valve in the dis-charge pipe on the pump. When the pump is stopped, the check valve will protect the pump against excessive pressure and will prevent the pump from running backward. The check valve should be installed between the gate valve and the pump nozzle in order to permit its inspection. The gate valve is also useful in priming and starting the pump.

Keep the suction pipe short and direct. Use a suc-tion pipe at least one size larger than the pump suc-tion nozzle. Keep the suction pipe free of all air pockets.

IMPORTANT

A spool piece should be installed in suction line so that the suction screen may be installed and re-moved.

BYPASS LINE

CAUTION OPERATION AT LOW FLOWS RESULTS IN PUMP HORSEPOWER HEATING THE LIQUID. A BYPASS MAY BE REQUIRED TO PREVENT VA-PORIZATION AND SUBSEQUENT PUMP DAM-AGE. MECHANICAL DAMAGE MAY RESULT FROM CONTINUOUS OPERATION AT FLOWS LESS THAN 25% OF DESIGN OPERATING POINT (see General Arrangement drawing & name-plate).

WARNING WHEN PUMP IS EQUIPPED WITH MANIFOLDED VENT AND DRAIN LINES, EACH LINE MUST BE EQUIPPED WITH AN INDIVIDUAL VALVE TO PREVENT ANY LIQUID FROM A HIGH PRES-SURE LINE FLOWING INTO A LOW PRESSURE LINE. THESE VALVES MUST BE KEPT IN THE CLOSED POSITION DURING PUMP OPERATION.

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SUCTION STRAINER

In a new installation, great care should be taken to prevent dirt, scale and welding beads from entering the pump. Even when piping has been previously flushed, it is difficult to break loose the oxides and mill scale which will become free when the pipe heats and cools several times. Numerous close running clearances are vulnerable to abrasive matter present in new piping. Foreign material may be large enough, or of sufficient volume, to jam a pump, with probable damage to both pump and drive equipment. Smaller size material passing through the pump can cause rapid pump wear and prema-ture pump failure.

This pump is provided with the exception that it will be pumping clean liquids (unless otherwise stated in the order and addressed in the proposal). Flows-erve pumps are provided with running clearances ranging typically from 0.005 inch(0.12 mm) to 0.030 inch(0.80 mm), depending on the service. It is im-practical to install a suction strainer to remove par-ticulate of this size. Such particles will normally pass through the pump without causing damage, provid-ing the concentrations are minor.

The possibility exists that, on shutdown of the pump, such particles can become trapped in the close run-ning clearances during coastdown, causing binding. Flowserve cannot recommend a procedure that will totally prevent such binding; however, we strongly suggest that systems be cleaned and thoroughly flushed prior to connecting the pump to the piping to minimize particles entering the pump. Starting and stopping of the pump should be MINI-MIZED as pumps are most susceptible to dirt during starts and stops.

In the event that binding on coastdown occurs, it is unlikely that the binding can be remedied by hand rolling the rotor, and partial disassembly may be re-quired to clean the affected parts. It should be noted that increased particle concentrations increase the probability of coastdown binding and seizures, as well as erosion damage.

CAUTION EXCESSIVE FORCE USED TO TRY TO FREE A BOUND ROTOR MAY CAUSE DAMAGE BEYOND MINOR CLEAN-UP AND REPAIR OF ROTOR PARTS.

Generally, a pump should not be installed without start-up strainer protection. The suction piping should be thoroughly flushed before installing the suction strainer and connecting the suction piping to the pump. The strainer should be installed in the inlet piping near the pump, making certain that it is located where it may be readily serviced (cleaned). Be sure, however, that the installed strainer will not distort the flow to the pump suction nozzle.

Do not install the strainer directly on the pump suc-tion nozzle. For a cone-type strainer, the down-stream end of the cone should be no closer than four (4) pipe diameters from the pump suction nozzle. Basket-type strainers typically introduce greater flow disturbances and should be installed at least six (6) pipe diameters from the pump suction nozzle.

The Flowserve standard for suction strainers con-sists of conical-shaped steel plate with 1/8” perfora-tions. The open area of the strainer should be a minimum of three times the area of the pump suc-tion.

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At all times when using suction strainers, it is critical that the pressure drop across the strainer be con-stantly monitored to ensure that the pump suction pressure does not fall below that required to prevent pump cavitation. Pressure (or vacuum) gauges should be installed on both sides of the strainer so that the pressure drop across the strainer can be monitored. During start-up of the system, the gauges should be monitored continuously. Consult the plant engineer or system designer for the allow-able pressure differential across the strainer prior to operating the pump. Pressure differential across the strainer and/or screen is typically no more than 2 – 3 psig. An increase in the differential pressure be-tween the two gauges indicates that the strainer or screen is becoming clogged with dirt and scale. Be-fore the pressure drop becomes so severe that cavi-tation occurs, the pump should be shut down and the strainer cleaned. Alarm settings to protect the pump from damaging cavitation and loss of suction need to be supplied by the plant engineer or system designer prior to operating the pump. Typical alarm settings to protect the pump from damaging cavita-tion and loss of suction would be 5 psig differential pressure across the strainer (screen). The suction piping should be arranged such that the ultimate strainer configuration (location) allows ready access for cleaning.

The strainer may be fitted with a finer screen to filter the inlet flow. When this is done, 40 mesh screen is typically used for start-up operation, at reduced flow rates. For final operation in a closed system, the suction strainers are normally removed after the sys-tem is cleaned. For critical pump applications, where continuous screening of suction flow is desir-able, and in open systems, 20 mesh screening is typically used for permanent strainers. At all times, when using screens and suction strainers, it is criti-cal that pressure drop across the screen and/or strainer be constantly monitored to ensure that the pump suction pressure does not fall below that re-quired to prevent cavitation.

When dirt and scale have been removed from the system, as indicated by no further change in pres-sure drop across the strainer with time, the start-up strainer may be removed or the screen may be re-placed with one having larger openings. If a perma-nent strainer will be used during normal operation, the pressure differential needs to be monitored on a continuous basis.

If a permanent strainer is not used, the start-up strainer needs to be temporarily reinstalled when-ever the system is opened up for repair or routine maintenance. As long as a suction strainer or screen remains in place, the differential pressure should be monitored on a regular basis.

CAUTION THE PRESSURE DROP ACROSS THE STRAINER IS A DIRECT REDUCTION IN THE NPSH AVAILA-BLE TO THE PUMP. NPSH AVAILABLE MUST ALWAYS EXCEED THE NPSH REQUIRED BY THE PUMP. THIS REQUIREMENT MAY LIMIT THE PUMP FLOW RATE, PARTICULARLY DURING START-UP OPERATION. ALARMS OR AUTO-MATIC PUMP SHUT-DOWN DEVICES SHOULD BE INSTALLED TO MINIMIZE THE POSSIBILITY OF PUMP DAMAGE. IT IS THE RESPONSBILITY OF THE PUMP OPERATOR TO OBTAIN THE AL-LOWABLE PRESSURE DROP ACROSS THE STRAINER FOR SAFE PUMP OPERATION FROM THE PLANT ENGINEER OR SYSTEM DESIGNER PRIOR TO OPERATION OF THE PUMP.

COUPLING ALIGNMENT CHECK

Refer to the section entitled “SHAFT/COUPLING ALIGNMENT” and perform a coupling alignment check as outlined. This check is recommended to insure the alignment has not been disturbed during the grouting of the bedplate or while installing suc-tion and discharge piping.

GIB BLOCK INSTALLATION

Gib blocks are installed to control the direction of thermal growth while maintaining pump-motor cou-pling alignment. They are installed after baseplate has been leveled and grouted, suction and dis-charge piping connected, and final shaft coupling alignment is completed.

Gib blocks are shipped loose and field installed at the site. The following procedure must be followed for correct installation of gib blocks.

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Step 1

Fully torque the hold-down bolts in the drive-end of pump feet to torque values listed in the instruction manual (refer to Pump Sectional Assembly Drawing in Appendix).

Step 2

Install the dowel pins in the pump drive-end feet by reaming the foot and baseplate for the tapered dowel provided.

Step 3

Position the gib blocks to obtain a 0.010 inch(.25 mm) clearance between the gib block and the side of the non-drive end pump foot as noted on the at-tached figure. Drill and tap the capscrew holes for the gib blocks.

Gib Block Installation Sketch

Step 4

Tighten the hold-down bolts for the gib blocks.

Step 5

Install the dowel pin in the gib blocks by reaming the block and baseplate for the tapered dowel provided.

Step 6

Tighten the hold-down locknuts on the non-drive end pump feed to establish a 0.002 inch(.05 mm) gap between the locknut and the pump foot.

INSPECTION OF OIL RINGS BEFORE START-UP

CAUTION A PROBLEM CAN ARISE WHEN PUMPS ARE TRANSPORTED BY VEHICLE OR WHEN BEING LIFTED BY A CRANE. JARRING OR UNEVEN LIFTING OF PUMPS CAN CAUSE THE OIL RINGS TO MOVE OUT OF POSITION. IF THE OIL RINGS ARE OUT OF POSITION AT START UP, THE BEARINGS WILL NOT GET LUBRICATION AND EVENTUALLY WILL FAIL.

BEFORE START UP TAKES PLACE, REMOVE THE 1/2 INCH NPT PLUGS ON THE TOP OF THE HOUSING AND CONFIRM THAT THE OIL RINGS ARE IN THEIR PROPER POSITION (SEE FIG-URE).

COMMISSIONING OF EQUIPMENT

Commissioning of all equipment must be performed in accordance with specifications set forth in Chapter 9 -`Commissioning’ from API Recommended Prac-tices 686/PIP REIE 686, First Edition.

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TECHNICAL DATA

These pumps are furnished for a particular service condition. Changes in the hydraulic system may affect the pump’s performance adversely. This is especially true if the changes reduce the pressure at the suction flange or if the liquid temperature is in-creased. In case of doubt, contact the nearest Flowserve Office.

SPECIFIC GRAVITY

The capacity and total head of liquid developed by a centrifugal pump are fixed for every point on the curve and are always the same for the same speed. Neither capacity nor total head will be affected by a change in the specific gravity of the liquid pumped. However, since the developed pressure and the brake horsepower to drive the pump are a function of the specific gravity of the liquid, both will be af-fected in direct proportion by any change in specific gravity. Therefore, a change in specific gravity will affect the discharge gage pressure. Any changes should be noted, in that they may overload the pump’s driver.

VISCOSITY

The pump is designed to deliver rated capacity at rated head for a liquid with a particular viscosity.

When contemplating operation at some viscosity other than that for which the pump was originally designed, the changed conditions should be referred to Flowserve Corp. for our recommendations.

CHANGING PUMP SPEED

Changing the speed of a centrifugal pump changes the capacity, total head and brake horsepower. The capacity will vary in a direct ratio with the speed, whereas the total head will vary as the ratio of the speed squared. The brake horsepower will vary as the ratio of the speed cubed, except in cases where the speed change also reduces the efficiency of the pump.

NET POSITIVE SUCTION HEAD (NPSH)

Any liquid, hot or cold, must be pushed into the im-peller of the pump by some absolute pressure, such as the atmosphere or the pressure of the vessel from which the pump takes its suction.

The head of liquid necessary to push the required flow into the pump is called the Net Positive Suction Head. This value, more commonly called NPSH, is measured above the vapor pressure of the liquid at the pumping temperature.

There are two kinds of NPSH. The NPSH required by the pump, as shown on the pump curve, is the head needed to cover the losses in the pump suc-tion. The second NPSH is that available in the sys-tem, taking into account friction loss in suction pip-ing, valves, fittings, etc. In all cases, the NPSH Available (measured above vapor pressure) must exceed the NPSH Required in order to push the liq-uid into the pump.

OPERATING PRECAUTIONS

WARNING DO NOT WIPE DOWN IN THE VICINITY OF RO-TATING PARTS. IF UNUSUAL NOISE OR VI-BRATIONS OCCUR, SECURE THE PUMP AS SOON AS POSSIBLE.

WARNING THE UNIT MUST NOT BE OPERATED UNLESS COUPLING GUARD IS BOLTED IN PLACE. FAILURE TO OBSERVE THIS COULD RESULT IN INJURY TO OPERATING PERSONNEL.

WARNING WHEN PUMP IS EQUIPPED WITH MANIFOLDED VENT AND DRAIN LINES, EACH LINE MUST BE EQUIPPED WITH AN INDIVIDUAL VALVE TO PREVENT ANY LIQUID FROM A HIGH PRES- SURE LINE FLOWING INTO A LOW PRESSURE LINE. THESE VALVES MUST BE KEPT IN THE CLOSED POSITION DURING PUMP OPERATION.

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WARNING OBSERVE EXTREME CAUTION WHEN VENTING AND/OR DRAINING HAZARDOUS LIQUIDS. WEAR PROTECTIVE CLOTHING IN THE PRES-ENCE OF CAUSTIC, CORROSIVE, VOLATILE, FLAMMABLE, OR HOT LIQUIDS. DO NOT BREATHE TOXIC VAPORS. DO NOT ALLOW SPARKING, FLAMES, OR HOT SURFACES IN VI-CINITY OF THE EQUIPMENT.

CAUTION TO MAINTAIN CLOSE RUNNING CLEARANCES AND BEARING LUBRICATION, THE PUMP SHOULD NOT BE OPERATED BELOW THE SPEED OF 1800 RPMS.

1. Never operate the pump with suction valve closed.

2. Never operate pump unless it is filled with liquid and vented.

3. Never operate the pump unless a liquid source is available.

PRE-OPERATIONAL CHECKS

At initial start-up and after the equipment has been overhauled.

1. Ensure pump and piping are clean. Before put-ting the pump into operation, it should be thoroughly flushed to remove the rust preventive as well as any foreign matter which may have accumulated during installation.

Take all possible care not to contaminate your sys-tem.

2. Clean and flush bearing housings. Fill reservoir with oil to the proper level (see “LUBRICATION”).

CAUTION CHECK THAT OIL RINGS ARE PROPERLY POSI-TIONED AND NOT HUNG-UP.

3. Ensure rotor is aligned within casing (see “MAIN- TENANCE”).

4. Turn rotor by hand or with strap to make sure it turns freely.

5. Check stuffing box.

A. If pump is equipped with a mechanical seal, ensure it is properly assembled and tightened (refer to “SHAFT SEALING” section).

CAUTION MOST CARTRIDGE SEALS ARE EQUIPPED WITH A SPACER BETWEEN THE GLAND PLATE AND DRIVE COLLAR. THIS SPACER MUST BE RE-MOVED BEFORE STARTING UNIT.

B. If pump is equipped with a packed box, insure box is properly packed (refer to “SHAFT SEALING” section).

6. Ensure coupling is properly aligned and lubri-cated, and pump and driver are properly dowelled (refer to “SHAFT/COUPLING ALIGNMENT” proce-dure).

7. Ensure coupling guard is in place.

8. Check torque of all bolting and plugs for tight-ness.

PUMP INSTRUMENTATION SET POINTS

The following set points apply to these DAD Pumps which use a ball/ball bearing arrangement.

Bearing metal temperature Normal 140o to 180oF.(60o to 82oC.) Alarm 190oF.(88oC.) Shutdown 200oF.(93oC.)

Bearing housing vibration Normal .1 to .3in/sec(2.5 to 7.6 mm/sec) Alarm .4 in/sec(10.2 mm/sec) Shutdown .5 in/sec(12.7 mm/sec)

INITIAL START-UP PROCEDURE

1. Close discharge valve if valve is not already closed.

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2. Prepare the driver for start-up in accordance with the manufacturer’s instructions.

3. Warm-Up Pump.

Avoid severe thermal shocks to the pump as a result of sudden liquid temperature changes. The pump must be preheated prior to start-up. Unless other-wise specified, the external temperature of the cas-ing must be within 100oF.(55.6oC.) of the tempera-ture of the liquid to be pumped at time of start-up. Due to the heavy metal sections, the casing will lag the liquid temperature during such changes, and severe temperature stresses and subsequent mis-alignment of machined fits may result. Pre-heating is accomplished by circulating a small amount of hot fluid through the casing by utilizing vents, drains or bypass from discharge. Preheat pump slowly at a rate not to exceed 100oF.(55.6oC.) per hour.

4. Prime pump and ensure pump suction valve is open.

CAUTION BEFORE STARTING OR WHILE OPERATING THE PUMP, THE CASING AND SUCTION LINE MUST BE COMPLETELY FILLED WITH THE LIQUID BE-ING PUMPED. THE ROTATING PARTS DE-PEND ON THIS LIQUID FOR LUBRICATION, AND THE PUMP MAY SEIZE IF OPERATED WITHOUT LIQ-UID.

5. Ensure pump recirculating line (if required) is open and free of obstructions.

6. Check that pump is vented by observing leakage from casing vent and seal piping vent. Close vent when liquid is emitted.

7A. If pump is equipped with a mechanical seal, make sure seal piping is turned on.

7B. If pump is equipped with a packed box, turn on cooling liquid.

8. Check pump rotating by starting unit momentarily. The direction of rotation is shown on “PUMP DATA SHEET” (1-1). Note the pump coasts to a gradual stop.

CAUTION IF PUMP STOPS ABRUPTLY WHEN DRIVER IS SHUT DOWN, INVESTIGATE FOR PUMP BIND-ING. TAKE NECESSARY REMEDIAL ACTION BE-FORE RESUMING OPERATION.

9A. Starting the driver (motor driven).

Prepare the driver for start-up in accordance with the manufacturer’s instructions.

Start the driver.

9B. Starting the driver (turbine driven).

Prepare the turbine for start-up in accordance with the manufacturer’s instructions.

Start the turbine and bring it up to speed quickly.

10. As soon as pump is up to rated speed, slowly open discharge valve. This will avoid abrupt changes in velocity and prevent surging in the suc-tion line.

OPERATING CHECKS

WARNING IN THE INTEREST OF OPERATOR SAFETY, THE UNIT MUST NOT BE OPERATED ABOVE THE NAMEPLATE CONDITIONS. SUCH OPERATION COULD RESULT IN UNIT FAILURE CAUSING IN-JURY TO OPERATING PERSONNEL.

CAUTION OPERATION AT LOW FLOWS RESULTS IN PUMP HORSEPOWER HEATING THE LIQUID. A BY-PASS MAY BE REQUIRED TO PREVENT VA-PORIZATION AND SUBSEQUENT PUMP DAM-AGE. MECHANICAL DAMAGE MAY RESULT FROM CONTINUOUS OPERATION AT FLOWS LESS THAN 25% OF DESIGN OPERATING POINT (see General Arrangement drawing notes).

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Immediately after start-up, and frequently during running, check the following:

1. Check suction and discharge pressure gauges.

2. Check pressure gauges on each side of suction strainer.

3. Check for excessive leakage at stuffing box gland area.

A. If pump is equipped with a mechanical seal, there should be no visible leakage to the naked eye.

B. If pump is equipped with stuffing box packing, leakage should be 1 oz. – 2 oz./min.(30 ml – 59 ml/min.)

4. Check for unusual noises.

5. Check oil rings to ensure they are rotating (eye protection required).

6. Check oil level in pump bearing housings.

7. Check for adequate flow of cooling liquids.

8. After unit has been operated a sufficient length of time to reach normal operating temperature and condition, the unit is to be shut down and a “HOT” cou-pling alignment check must be made (refer to “SHAFT/COUPLING ALIGNMENT” procedure).

WARNING OPERATION OF THE UNIT WITHOUT PROPER LUBRICATION CAN RESULT IN OVERHEATING OF THE BEARINGS, BEARING FAILURES, PUMP SEIZURES AND ACTUAL BREAKUP OF THE EQUIPMENT EXPOSING OPERATING PERSON-NEL TO INJURY.

NORMAL START-UP

The starting procedure to be followed for normal start-up is the same as that for initial starting.

SECURING THE PUMP

1A. Motor Driven.

De-energize driver circuit.

1B. Turbine Driven.

Stop turbine-driven pumps by manually tripping the overspeed trip.

2. The pump should be shut down rapidly to protect the internal wearing parts which are lubricated by the liquid being pumped.

Lubrication is reduced when a pump is stopped slowly, and seizure could result.

NOTE

If pump stops abruptly when driver is shut down, investigate for pump binding. Take necessary reme-dial action before restarting pump.

3. Close the pump suction and discharge valve.

4. Close valve in bypass line.

5. Turn off auxiliary oil pump and cooling liquid (when supplied).

6. If pump is subjected to freezing temperatures, the pump must be drained of liquid to prevent damage to pump.

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The following chart presents information that is useful in the analysis of some typical pump performance prob-lems. The Pump Data Sheet, assembly drawings, parts list, and performance curve provided with each unit should be available when investigating performance problems. Assembly and disassembly procedures are in-cluded in the “MAINTENANCE” section.

FOR 24-HOUR EMERGENCY REPAIR SERVICE, CALL 1-800-54 7-8671.

A listing of the Flowserve Pump Repair Centers is included at the end of this section.

TROUBLESHOOTING CHART

Trouble Possible Cause Corrective Action

Insufficient capacity and/or pres-sure

Suction Pressure or speed too low Open suction valve wide. Check power supply for correct voltage.

Incorrect direction of rotation.

A. If pump is motor driven: Refer to motor instruction manual

and reconnect motor leads.

B. If pump is turbine driven: Contact turbine manufacturer.

Excessive amount of air or vapors in the fluid

Check suction system for air leak-age and correct. Vent air. Tighten flange bolts.

Foreign material in suction line Dismantle suction line and remove

foreign material.

Mechanical Defects: Impeller damaged. Sheared impeller keys. Broken or damaged coupling.

Dismantle pump and correct.

Pump loses prime after starting Insufficient liquid supply Ensure that suction valve is wide open. Check for proper liquid level.

Excessive amount of air or vapor in the liquid

Check suction system for air leak-age and correct.

Clogged impeller Dismantle pump and correct.

Suction pipe clogged. Remove foreign material.

Pump Vibration Loose Mounting or coupling bolts. Tighten bolts.

Coupling Check alignment and correct.

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(Cont’d) Pump vibration

Air or gas in liquid Vent air and check suction for leaks. Tighten flange bolts.

Foreign material in impeller causing unbalance

Dismantle pump and remove any foreign material.

Mechanical Defects: Shaft bent. Bearings worn.

Dismantle pump and replace part or parts causing vibration.

Pump overloads driver Speed too high

A. If pump is motor driven: Refer to motor instruction manual and check power supply for correct frequency.

B. If pump is turbine driven: Check steam pressure to turbine.

Pump bearings seize or rotating element binds

Dismantle pump and replace part or parts causing seizures, or binding.

Pump stops abruptly Pump binding at running fits Dismantle pump and realign rotor in casing.

High pump thrust bearing tem-perature rise

Improper lubrication Replenish oil with proper grade lu-bricant.

Rotor not centered in volutes Check rotor centralization.

Insufficient oil. Contaminated oil.

Add oil. Drain and clean reservoir. Refill with clean oil.

High Oil Temperature Connect cooling liquid to lube oil cooler.

Mechanical seal gland (when used) overheats

Insufficient cooling water to seal Obstruction in seal water piping. Remove and clean.

Mechanical seal not properly set. (Check for cracked stationary face/ rotating face)

Refer to “SHAFT SEALING” pages.

Pump is noisy Cavitation Check that pump is primed, check for high suction temperature, in-crease static head, check for ob-struction in suction line.

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(Cont’d) Pump is noisy

Loose Parts

Tighten or replace defective part.

Noise in driver Check driver with stethoscope.

Check driver instruction book for troubleshooting instructions.

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FLOWSERVE CORPORATION PUMP SERVICE CENTERS

Baton Rouge SC 4152 Rhoda Drive Baton Rouge, LA 70816 Phone: 225-293-5780 Fax: 225-281-8134

Boothwyn SC 11 Creek Parkway Boothwyn, PA 19061 Phone: 610-859-0700 Fax: 610-859-0711

Cleveland SC 6250 Halle Drive Cleveland, OH 44125 Phone: 216-524-6155 Fax: 216-642-5741

Fairfield SC 142 Clinton Road Fairfield, NJ 07004 Phone: 973-227-4565 Fax: 973-227-6615

Leduc/Edmonton SC 4405 70th Avenue Leduc, Alberta Canada T9E 7E6 Phone: 780-986-7100 Fax: 403-986-4854

Sarnia SC 235 Henry Drive RR No. 4 Sarnia, Ontario Canada N0N 1T0 Phone: 519-336-3614 Fax: 519-336-7410

Texas City SC 146 FM 519 Building 4C Texas City, TX 77568 Phone: 409-935-1977 Fax: 409-935-2269

Woodbridge SC 120 Vinyl Court Woodbridge, Ontario Canada L4L 4A3 Phone: 905-856-1140 Fax: 905-856-2010

Beaumont SC 2920 West Cardinal Drive Beaumont, TX 77705 Phone: 409-842-5594 Fax: 409-842-5958

Carson SC 24351 S. Wilmington Carson, CA 94510 Phone: 310-522-0925 Fax: 310-522-0758

Customer – Field Service 942 Memorial Parkway Phillipsburg, NJ 08865 Phone: 908-859-7066 Fax: 908-859-7836

Greer SC 2431 S. Highway #14 Greer, SC 29650-8201 Phone: 864-879-7276 Fax: 864-879-0997

Parts Distr. Center (Moosic) Rocky Glen Road Rocky Glen Industrial Park Moosic, PA 18507 Phone: 717-451-2200

Scranton Parts 942 Griffin Pond Road Clark Summit, PA 18411 Phone: 570-586-8800 Fax: 570-587-5006

Vancouver SC 10400 N.E. 13th Street Vancouver, WA 98686 Phone: 360-573-5211 Fax: 360-574-7656

Benecia SC 6077 Egret Court Benecia, CA 94510 Phone: 707-745-3773 Fax: 707-746-1568

Charlotte SC 4816 Worth Place Charlotte, NC 28216 Phone: 704-399-0446 Fax: 704-393-7296

Elgin SC 695 Church Road Elgin, IL 60123 Phone: 847-742-9510 Fax: 847-742-9593

Houston SC 6832 Wynnwood Lane Houston, TX 77008 Phone: 713-868-6666 Fax: 713-868-6630

Pittsburgh Parts 1885 Mayview Road Bridgeville, PA 15017 Phone: 412-257-4600 Fax: 412-257-3162

Tampa SC 6405 Badger Drive Tampa, FL 33610 Phone: 813-621-8865 Fax: 813-626-1274 Wasilla SC 2051 Foundry Way Wasilla, AK 99654 Phone: 907-376-0550 Fax: 907-376-0659

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LUBRICATING OIL

WARNING OPERATION OF THE UNIT WITHOUT PROPER LUBRICATION CAN RESULT IN OVERHEATING OF THE BEARINGS, BEARING FAILURES, PUMP SEIZURES AND ACTUAL BREAKUP OF THE EQUIPMENT, EXPOSING OPERATING PERSON-NEL TO INJURY.

Remember that oil requires frequent replenishment at normal operating temperatures and very frequent replenishment at elevated operating temperatures. Oil is always subject to gradual deterioration from use and contamination from dirt and moisture. This deterioration and contamination will, in time, be harmful to the bearings and can cause premature wear. For these reasons, oil should be checked for contamination and deterioration regularly.

The frequency of oil change depends on the operat-ing conditions and the quality of the lubricant. Oil should be checked for deterioration and contamina-

tion weekly during periods of operation. Mineral oils oxidize and should be replaced at no more than three month intervals when operated continuously in the 160o-180oF.(71o-82oC.) range. Longer intervals between replacement may be possible at lower op-erating temperatures, but three month intervals are recommended to protect against normal oxidation, contamination and deterioration.

OIL SPECIFICATIONS

Straight mineral oils without additives are generally preferred for rolling element bearing lubrication. It should preferably be of the turbine type and not con-tain free acid, chlorine, sulfur or more than a trace of free alkali. Quality mineral oils with a minimum Vis-cosity Index (VI) of 95 are recommended. Lubricat-ing oils are identified by an ISO Viscosity Grade (VG) Number. The VG number is the viscosity of the oil at 40oC.(104oF.) in centistokes. In the majority of instances, a turbine oil with a VG Number of 68 (nominally equivalent to SAE 20) will meet rolling element bearing lubrication requirements (see OIL TEMPERATURE).

ASTM STANDARDS for mineral oils

Oil Characteristics Operating Temperatures

60o-100oF.(16o-38oC.) 101o-180oF.(38o-82oC.)

Saybolt Viscosity (SSU) 100oF.(38oC.)

158 Seconds 335 Seconds

Pour Point 20oF.(-7oC.) 20oF.(-7oC.)

Flash Point 400oF.(204oC.) 400oF.(204oC.)

Recommended ISO Viscosity Grade (VG) Number

32 68

In a majority of instances, ISO 68 (nominally equivalent to SAE 20 turbine type oil) will meet the above specifica-tions.

LUBRICANT MUST BE COMPATIBLE WITH ALL PARTS REQUIRING LUBRICATION.

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OIL TEMPERATURE

Oil temperature entering the plain/thrust end bear-ings should be maintained between 60oF.(15.6oC.) and 180oF.(82oC.).

Alarm temperature is 190oF.(88oC.) with shut down temperature set at 200oF.(93oC.).

If bearing oil temperature exceeds the above men-tioned limits, cooling liquid to the lube oil cooler will have to be increased.

IMPORTANT

The minimum bearing oil temperature is 60oF. (16oC.). If necessary, prior to startup, one of the fol-lowing procedures should be employed:

1. Drain the oil in the bearing housing(s) and re-place with warm oil.

2. Heat the bearing housing(s) using heat tape (or other suitable means).

3. Circulate warm liquid through the cooling jacket or immersion cooler (if supplied).

4. Utilize oil with a lower viscosity, or VG number, or consider using a synthetic hydrocarbon oil with a low pour point to give a viscosity similar to that of ISO 68 (for maximum oil operating temperatures of 180oF.) or ISO 32 (for maximum oil operating temperatures of 120oF.).

NOTE

ISO 68 is recommended for continuous operating oil temperatures between 100oF.(38oC.) and 180oF. (82oC.), with a minimum startup temperature of 60oF.(16oC.); ISO 32 may be considered for continu-ous operating oil temperatures between 60oF. (16oC.) and 120oF.(49oC.), with a minimum startup temperature of 40oF.(4oC.). For startup when oil temperature is below 40oF.(4oC.), oil preheating is recommended.

CLEANING THE LUBRICATION SYSTEM PRIOR TO OPERATION

Before operating the pump, the lubrication system should be thoroughly cleaned to remove any foreign matter that may have accumulated during shipment, storage or installation.

To clean the lubrication system, proceed as follows:

1. Loosen the bearing end covers and flingers and remove drain plugs.

2. Flush out the bearing housings with kerosene or other suitable solvent.

3. Flush the bearing housings with oil. Oil should be compatible with lubricating oil that will be used.

4. After flushing, replace drain plugs. Reassemble bearings and torque end cover bolting. (Refer to “MAINTENANCE” section.)

5. Refer to driver instruction book for instructions covering flushing of driver bearings.

TRICO OIL SETTING

Assemble oiler to bearing housing. Adjust oiler and fill bearing housing with oil per “Trico Oil Level Set-ting” drawing in Appendix.

WARNING OPERATION OF THE UNIT WITH INCORRECT OIL LEVEL SETTING CAN RESULT IN OVER-HEATING OF THE BEARINGS, LACK OF LUBRI-CATION TO THE BEARINGS, BEARING FAIL-URES, PUMP SEIZURES AND ACTUAL BREAKUP OF THE EQUIPMENT, EXPOSING OP-ERATING PERSONNEL TO INJURY.

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MECHANICAL SEAL

Your pump is typically shipped with the mechanical seal already installed. All mechanical seals are of the cartridge type design. The mechanical seal is designed to suit each application. This creates the correct seal loading face when seal gland is bolted in place.

Cartridge type mechanical seals are preset at the seal manufacturer’s facility and require no field set-tings. The seal installation should be checked be-fore startup.

Refer to the mechanical seal manufacturers drawing and instructions found in the Appendix of this man-ual for detailed information.

MECHANICAL SEAL REMOVAL

To remove mechanical seal from pump:

1. Install setting plates/eccentric washer in place.*

2. Loosen drive collar.

3. Remove gland bolting.

4. Slide sleeve with mechanical seal from shaft.

Seal may be disassembled/inspected/reassembled per seal manufacturer’s drawing and instructions in Appendix of this manual.

*NOTE

After reassembly of seal, setting pl

vintage parts marketing - flowserve...baseplate grouting requirements. copies of api recommended...

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